Expandable chuck

ABSTRACT

The process provides an expandable chuck with a variable diameter bulb having a variable wall thickness, the chuck being operatively designed to stretch the bulb to reduce its diameter for insertion into a photoreceptor pipe and upon relaxation to the compress the bulb so as to increase its diameter. The design provides a universal chuck to reduce the cost of changing to different diameter chucks in accommodating different size photoreceptors during the coating and drying process.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of, and claims the benefit ofpriority to, U.S. patent application Ser. No. 11/155,500, filed Jun. 20,2005, the entire contents of which is incorporated herein by reference.

BACKGROUND

All references cited in this specification, and their references, areincorporated by reference herein in their entirety where appropriate forteachings of additional or alternative details, features, and/ortechnical background.

Disclosed in the embodiments herein is an expandable chuck device forinserting into, holding and sealing a photographic imaging device duringdip coating and drying operation.

Electrophotographic imaging members are known. Electrophotographicimaging members include photosensitive members, known as photoreceptors.Photosensitive members commonly utilized in electrophotographic(xerographic) processes may comprise, for example, a flexible belt or astructure such as a rigid drum.

Rigid electrophotographic imaging members, including drums or pipes, maybe coated by many different techniques such as spray coating, immersionand dip coating. Dip coating is a coating method typically involvingdipping a substrate in a coating solution, such as organicphotoconductor coating, and taking up the substrate for the drying step.In dip coating, the coating thickness depends on the concentration ofthe coating material and the take-up speed (i.e., the speed of thesubstrate being lifted from the surface of the coating solution). It isknown that the coating thickness generally increases with the coatingmaterial concentration or viscosity and with the take-up speed.

One method for dip coating electrophotographic cylinders, pipes or drumsto form an organic photoconductor layer thereon comprises obtaining adrum having an outer surface to be coated, an inner surface walldefining a void, and an upper opening end and a lower opening end incommunication with the void, immersing the drum in a flowing liquidcoating material while maintaining the axis of the drum in a verticalorientation, maintaining the outer surface of the drum in a concentricrelationship with the vertical interior wall of the cylindrical coatingvessel while the drum is immersed in the coating material, the outersurface of the drum being radially spaced from the vertical interiorwall of the cylindrical coating vessel, maintaining laminar flow motionof the coating material as it passes between the outer surface of thedrum and the vertical interior wall of the vessel, and withdrawing thedrum from the coating vessel.

An electrophotographic receptor drum may have the form of a relativelynarrow cylinder or pipe. As coating of only the outside of aphotoreceptor drum may be desired, in particular to avoid loss of thecoating solution, a plug may be affixed at the top end of anelectrophotographic drum before the immersion into the coating substanceto prevent the coating substance from entering the void due to positiveair pressure therein. A chuck member may be relied upon both to seal thetop of the photoreceptor drum to prevent fluid from entering the openingin the drum by displacing air in the opening (i.e., the chuck memberacting as a plug) and also carry it through this entire operation. Thechuck may have a seamless plug shape to prevent the coating solutionsfrom penetrating inside the drum by air leaking along the seam. Thechuck device may be configured to have a stem portion anchored in theplug portion. The plug portion is inserted in the open top end of thephotoreceptor drum and connected to a carrier assembly for transportingthe photoreceptor through the coating and drying operation.

The use of a single rubber bladder for sealing the drum and for movingthe drum from one process step to another has worked very well over theyears but has the disadvantage of not allowing different diameters ofphotoreceptors to be coated using a single chuck. In fact, the solid orinflatable chuck system requires a specifically fitted single chuck foreach of the different size diameter drums. As a consequence, multipledifferent diameter photoreceptors cannot be treated and transportedthrough the same installation. As part of the task of coating differentdiameter photoreceptors, a plant operation may require that theindividual chucks must be continually exchanged or “changed out”,commensurate with the size and number of the different photoreceptortubes. Chucking devices used in production may use a compressed“doughnut” to perform these functions. Many new products being scopedfor dip coating production have varying diameters (i.e., 24, 40, 60 mm).Of course, if there are, for example, 1200 chucks in each of say two dipcoating production lines and three different drum diameters are scopedto be coated, changing over all of these chucks would not be a trivialmatter. This complicated aspect of the operation of the coating/dryingprocess can be very time-consuming as well as adding to the cost of sucha facility by the requirement of a great number of differently sizedchucks. Moreover, the single diameter chucks are expensive and requiresubstantial downtime for change-over.

There is also a labor cost in changing chucks from one diameter to thenext. There is also a material loss expected in changing out chucks dueto incorrectly installed chucks resulting in the simultaneous loss ofseveral photoreceptor drums and down time required for repair andrecovery. When using single diameter chucks, every time a drumphotoreceptor of a different diameter is coated, all of the chucks mustbe changed over to the new size. For example, chucking of a drumphotoreceptor for coating involves gripping the pipe with sufficientforces to prevent movement, pull-off or rotation during processing.Chucking must seal the inner wall of the pipe to prevent solution fromfilling the interior. Chucks must also locate the pipe at a specificpoint and ensure the pipe is vertically plumb. All of these conditionsfrequently must be met in environments of solvent laden air, hightemperature and humidity, and in a Class 100 clean-room.

A universal coating chuck would require no change-over or downtime. Itis therefore one object of the present invention to develop a UniversalCoating Chuck which uses a “bulb-type” gripping member. This bulb ismolded in the larger diameter state, such that to reduce the chuckdiameter for insertion into the inner diameter of the pipe, it needs tobe pulled axially.

REFERENCES

Reference is made to United States patents which disclose dip-coating arigid cylindrical assembly with an electrophotographic coating solution.

U.S. Pat. No. 5,788,774 to McCumiskey et al., issued Aug. 4, 1998,discloses a substrate coating assembly employing a plug member forselectively coating a hollow cylindrical substrate wherein the plugmember is fabricated from a non-wetting material.

U.S. Pat. No. 5,693,372 to Mistrater et al., issued Dec. 2, 1997,describes a process for dip coating drums comprising providing a drumhaving an outer surface to be coated, an upper end and a lower end,providing at least one coating vessel having a bottom, an open top and acylindrically shaped vertical interior wall having a diameter greaterthan the diameter of the drum, flowing liquid coating material from thebottom of the vessel to the top of the vessel, immersing the drum in theflowing liquid coating material while maintaining the axis of the drumin a vertical orientation, maintaining the outer surface of the drum ina concentric relationship with the vertical interior wall of thecylindrical coating vessel while the drum is immersed in the coatingmaterial, the outer surface of the drum being radially spaced from thevertical interior wall of the cylindrical coating vessel, maintaininglaminar flow motion of the coating material as it passes between theouter surface of the drum and the vertical interior wall of the vessel,maintaining the radial spacing between the outer surface of the drum andthe inner surface of the vessel between about 2 millimeters and about 9millimeters, and withdrawing the drum from the coating vessel.

U.S. Pat. No. 5,725,667 to Petropoulos et al., issued Mar. 10, 1998,discloses a dip coating apparatus including: (a) a single coating vesselcapable of containing a batch of substrates vertically positioned in thevessel, wherein there is absent vessel walls defining a separatecompartment for each of the substrates; (b) a coating solution disposedin the vessel, wherein the solution is comprised of materials employedin a photosensitive member and including a solvent that gives off asolvent vapor; and (c) a solvent vapor uniformity control apparatuswhich minimizes any difference in solvent vapor concentrationencountered by the batch of the substrates in the air adjacent thesolution surface, thereby improving coating uniformity of thesubstrates.

U.S. Pat. No. 6,214,419 to Dinh et al., discloses a process forimmersion coating of a substrate including positioning a substratehaving a top and bottom within a coating vessel having an inner surfaceto define a space between the inner surface and the substrate, fillingat least a portion of the space with a coating mixture; stopping thefilling slightly below the top of the substrate, initiating removal ofthe coating mixture at a gradually increasing rate to a predeterminedmaximum flow rate in a short predetermined distance, and continuingremoval of the coating mixture at substantially the predeterminedmaximum flow rate to deposit a layer of the coating mixture on thesubstrate.

U.S. Pat. No. 5,829,759 to Swain et al. issued Nov. 3, 1998 discloses achuck assembly for engaging the inner surface of a hollow substratecomprising a housing having an open end and defining a passageway incommunication with the open end; a partially hollow elastic bootdefining an entry hole and an inner surface wherein the boot whenstretched decreases in cross-sectional dimension, and wherein the bootengages the housing, whereby the hollow portion of the boot is incommunication with the passageway; and a movable, boot stretching memberdisposed in the passageway and adapted to engage the inner surface ofthe boot, wherein movement of the member in a direction to stretch theboot decreases the cross-sectional dimension of the boot, therebypermitting insertion of the boot into the substrate, and whereinmovement of the member in the opposite direction increases thecross-sectional dimension of the boot, thereby permitting engagement ofthe boot against the inner surface of the substrate.

SUMMARY

Aspects of the invention include:

an expandable chuck comprising a housing having a first open end and asecond open end, an inside and an outside surface, inside surface,defining a passageway in communication with the first open end and thesecond open end; a moveable plunger assembly comprising a first portionexterior to the first opening end of the housing having an a terminalend, a second portion extending through the passageway of the housing,and a third portion exterior to the second opening end of the housingand terminating in an expanded end; a stretchable hollow bulb defining afirst open end and a second open end, wherein the bulb comprises a wallof varying thickness having an inner surface, defining a cavity, and anouter surface, and wherein the first open end of the bulb is incommunication with the second open end of the housing and the secondopen end of the bulb abuts the expanded end of the plunger; wherein theplunger assembly is operationally configured with respect to the bulb tocause the bulb to expand in diameter for a period of time when theterminal end of the first portion of the plunger is moved in a distaldirection to the first open end of the housing, and to decrease indiameter for a period of time when the terminal end of the first portionof the plunger is moved in a proximal direction to the first open end ofthe housing;

an expandable chuck comprising a plunger assembly having a slidableplunger capable of moving in a first direction and a second direction;an elastomeric bulb having an outer surface and an inner surfacedefining a wall, the inner surface defining a void, and having a firstopen end and a second open end in communication with the void; whereinthe plunger assembly is operatively configured with respect to theelastomeric bulb to cause the void of the elastomeric bulb to elongateabove a directional axis when the slidable plunger is moved in thesecond direction but diminishes along the same directional axis when theslidable plunger is moved in the first direction; and wherein theelastomeric bulb walls are configured to be thicker at the first openend and the second open end than wall at a midpoint between first andsecond open end; and

a chuck and photoreceptor drum assembly comprising a drum photoreceptorhaving an outer surface and an inner surface defining a wall, the innersurface defining a void, and a first open end and a second open end; anelastomeric bulb positioned in the void of photoreceptor, theelastomeric bulb having an outer surface and an inner surface defining awall, the inner surface defining a void, and having a first open end anda second open end; wherein the elastomeric bulb wall is thicker near thefirst and second open end of the bulb than at a point between first andsecond open end; and a plunger assembly attached to the elastomeric bulbcapable of altering the shape of the void of the bulb, a portion of theplunger assembly extending from the first or the second open end of thedrum photoreceptor.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detailed description reference is made to the illustrativefigures listed below.

FIG. 1 illustrates an initial expanded stage cross-sectional lengthdiagram of one embodiment of the universal expandable chuck device;

FIG. 2 illustrates a further expanded stage cross-sectional lengthdiagram of one embodiment of the universal expandable chuck device;where FIG. 2A illustrates a cross-section of FIG. 2 along line 2A-2A;and FIG. 2B illustrates a cross-section of FIG. 2 along line 2B-2B; and

FIG. 3 illustrates another, more fully expanded stage cross-sectionallength diagram of one embodiment of the universal expandable chuckdevice.

Other aspects of the present invention will become apparent as thefollowing description proceeds and upon reference to the Figures whichrepresent preferred embodiments.

DETAILED DESCRIPTION

In embodiments there is illustrated a variable wall thickness, variablediameter expandable universal chuck device for holding and sealing, arigid or flexible substrate having a void of different cross-sectionaldimensions, allowing for processing in one operation. The embodiments ofsuch substrate may be variously described in terms of a substantiallycylindrical housing such as a pipe, tube or drum. Such a substrate maybe understood to include drum-type electrophotographic imaging members.Such chucks may be used for the immersion-coating or dip-coating ofdrum-type electrophotographic imaging members, and the subsequenttransport for drying of the substrate.

In one embodiment, a universal coating chuck having sealing and holdingproperties comprises a flexible “bulb-type” gripping member so as to fita variable diameter number of substrates. A bulb according to theembodiment of this invention is molded in the larger diameter state. Thebulb is attached to a plunger assembly operationally configured toreduce the cross-sectional diameter of the bulb enough for fittingslidingly into the inside diameter of a pipe, tube or drum when theplunger of such assembly is pulled axially away from the bulb, but toallow for an increase in the cross-sectional diameter of the bulb whenthe assembly is pulled toward the bulb.

Attempts to use a bulb molded in a smaller diameter state andcompressing it to achieve a larger diameter have resulted in deviceswherein the bulb material tends to fold over on itself, rather than toexpand. It has also been found that in embodiments wherein bulbs aredecreased in inner diameter, when a uniform wall thickness “bulb” isutilized, the stretching of the elastic material may also be uniform,thereby causing “scalloping” of the cross-sectional diameter as it isreduced. This may compromise the seating of the bulb, preventing thesealing of the inside diameter of the pipe with the bulb.

A variable wall thickness of bulb modeled using a Finite ElementAnalysis was found to overcome the problem associated with uniform wallthickness. Thus by selectively changing the wall thickness of the bulb,one can affect the deformity of the bulb in a selective manner to allowfor gripping, sealing and locating various inside diameter pipes forprocessing.

Aspects disclosed herein include a universal coating chuck utilizing avariable wall thickness, variable diameter silicone rubber bulb moldedin a large diameter state operatively configured in the chuck with aplunger such that when the plunger is pushed axially, the diameter ofthe bulb is reduced for insertion into a photoreceptor pipe while whenit is pulled axially, the diameter of the bulb increases to allow forcontact of the bulb with the drum, tube, etc., into which it isinserted. The bulb may be allowed to be compressed to fit within thepipe and then relaxed within the pipe to effectively grip, seal, andlocate the pipe during coating and drying steps. The universal chuck mayinclude a full range of flexibility, for example, without limitation, 24to 60 mm diameters.

Coating mixtures in dip coating may comprise materials typically usedfor any layer of a photosensitive member including such layers as asubbing layer, a charge barrier layer, an adhesive layer, a chargetransport layer, and a charge generating layer, such materials andamounts thereof being illustrated for instance in U.S. Pat. Nos.4,265,990, 4,390,611, 4,551,404, 4,588,667, 4,596,754, and 4,797,337.

The desired elasticity of the bulb-like gripping means material may beachieved using a rubber-like compound selected, among others, fromsilicon rubber and an elastic polymer. For example, an adjustablediameter silicon rubber chuck may be configured to fit all sizes oforganic photoconductor that are immersion- or dip-coated in ahigh-density dip operation. The universal chuck bulb may be molded in alarge diameter shape and then stretched to reduce the diameter forinsertion into the photoreceptor drum.

FIG. 1 shows one embodiment of an expandable chuck device 10 comprisedof a hollow housing portion 30 and a bulb portion 20. The housingportion 30 has an open first end 32 and a second open end 33 encasing apassageway 35 for axially housing a movable stretching device whichincludes in sequence, an actuator portion 25, a shaft portion 34, a bulbstretching portion 40, and a tip portion 15. The bulb 20 may be engagedat its first open end 36 to the housing second end 33 and at its secondend 37 to the tip member 15 of the bulb-stretching portion 40, forexample, by threads. The chuck housing 30 may be in the generalconfiguration of a hollow tube, pipe or other approximately cylindricalconfiguration having open ends. The contour of the cross-section of thebulb member 20 is diagrammed in the stretched configuration so as toslidingly fit inside a substrate member, in particular, a photoreceptordrum substrate 100. Proximal to the housing second end portion 33, anaffixed flange or ring washer 31 may be configured to facilitate a stopfor a measured length insertion of the chuck device 10 into thesubstrate end (not shown), the inserted chuck device 10 thus includingmainly the bulb portion 20 inside the substrate. The housing 30preferably is an integral piece, especially a single piece. According toone embodiment, the cone-shaped tip portion 15 may have a smallercross-sectional dimension than the rest of the substrate whereby thecone shape is intended to facilitate easier insertion of the chuckdevice into the photoreceptor drum substrate.

FIGS. 2 and 3 disclose different expansion states of an expandable chuckembodiment in FIG. 1. Specifically, FIG. 2 is diagramed to show a bulbconfiguration at partial expansion achieving an intermediatecross-sectional diameter. The embodiment provides an intermediatecompression or expansion adjustment of bulb 20′ involving repositioningof the stretching rod 34 and moving the stretching actuator 25 away fromthe bulb end thereby effectively withdrawing the tip portion 15 from aninterior space of a particular sized substrate interior space (notshown) and shortening the length of the bulb (stretching device portion40 that is encased within an interior or void 45 of the bulb 20. FIG. 3is a diagram illustrating the bulb member 20″ at its fullest expansionsuch that the bulb 20″ may tightly grip and hermetically seal theinterior space of a relatively large diameter photoreceptor drumsubstrate 100′.

The chuck housing 30 may be fabricated from a material which has one ormore of the following properties: high temperature resistance, low mass,minimal heat sinking, rigidity with resilient strength, and durability.Suitable materials to fabricate such a the structure may include, forinstance, a plastic like ULTEM™; (a polyetherimide resin) and VALOX™ (athermoplastic polyester resin), both available from the General ElectricCompany, or a metal like aluminum, stainless steel, iron, nickel,copper, or bronze. The housing 30 of the chuck embodiment shown mayinclude a plurality of slots or holes 38 through the housing andextending to the open first end 32 of the housing 30.

The bulb 20 is preferably fabricated from a material having one or moreof the following properties: high temperature resistance, elasticity,and durability. The bulb material may be any suitable polymericcomposition including an elastomer as for example silicone rubber (e.g.,silicone rubber compound no. 88201 available from Garlock Division ofColtec Industries), VITON™, or the like. The bulb member may befabricated from an elastic material having the same hardness valuethroughout the bulb body. In a preferred embodiment, however, thematerial of the bulb ends at or near the housing attachment areas 20′a,20′c (20″a, 20″c), is progressively thicker than the material of thebulb middle section 20′b (20″b). For instance, this substantial portionof the bulb may have a durometer numerical hardness ranging from about25 to about 40, or about 35; the end sections of the bulb member mayhave a durometer hardness ranging from about 45 to about 60, or about50. The sections having different degrees of hardness may be the same ordifferent material. This dual material thickness and resulting durometerhardness affords retention of the bulb inside the substrate during thechucking operation and minimizes or eliminates the need to use aseparate clamp to secure the chuck to the substrate.

FIG. 2A illustrates a cross-section of FIG. 2 along line 2A-2A,detailing an embodiment of the bulb 20 and the housing 30 where theengaged surfaces of both the bulb first end 36 and the housing secondend 33 include threads 21 to promote retention of the bulb 20 to thehousing 30 during the chucking operation and to minimize or eliminatethe need to use a separate clamp to hold the bulb to the housing. Inembodiments of the instant invention, either the outside surface of theend portion 33 of the housing or the inner surface of the first endsection 36 of the bulb, or both, contain threads 21. In embodiments, ametal or hard plastic threaded insert can be molded or positioned intothe bulb ends 36 and 37, in which case, the threaded insert isconsidered herein as a part of the bulb 20. Threading increases theamount of the bulb 20 that contributes to the retention forces byrequiring more of the bulb end to stretch radially before the bulb willslip off the housing.

In the process of operation, the bulb-stretching member 40 (e.g. shownin FIG. 1) in the form of a rod is axially positioned in the passageway35 and adapted to engage the inner surface of the distal bulb end orsecond bulb end 37 adjacent the tip 15, the proximal bulb end or bulbfirst end 36 is preferably attached to the second chuck housing end 33.The stretching member 40 is preferably a single integral piece and maybe fabricated from wood, plastic or a metal such as stainless steel,aluminum, or iron. In embodiments, the shaft portion 34 of thestretching member 40 may be a solid or hollow rod.

FIG. 2B illustrates a cross-section of FIG. 2 along line 2B-2B,detailing an embodiment of the tip 15 of the bulb stretching member 40engaged to the bulb 20 by threads 22. The tip 15 may be engaged to thebulb stretching member 40 by threads 23. The advantage of coupling thestretching member 40 to the bulb 20 is that one can increase thecross-sectional dimension of the boot by proximal movement of the memberactuator 25 to effect a size that is generally impossible to attain byrelying solely on the inherent elastic or restorative properties of thebulb material after stretching, not to mention the concomitanthysteresis effect usually encountered by this deformation. In essence,by coupling the stretching member to the bulb, one can compress orexpand the bulb by pulling the stretching member in a proximal positionto achieve the desired wider cross-sectional dimension and thus providemore holding or clinging force. To effect efficient coupling of themember to the distal bulb end surface, one may also contemplateemploying an adhesive or any other suitable method and device.

Operation of the embodiments depicted in FIGS. 1-3 may proceed asfollows. The bulb stretching member 40 moves in the tip 15 in a forwarddirection A to push against the second bulb end 37, thereby stretchingthe bulb 20 into a substrate accommodating configuration, therebyreducing the cross-sectional dimension or radial dimension of the bulb20. The bulb 20 now having the reduced cross-sectional dimension, isinserted into the substrate 100, 100′. To achieve the desired holdingforce the bulb stretching member 40 is moved in the reverse direction B,allowing the bulb 20 to expand, thereby increasing the cross-sectionaldiameter of the bulb 20 to allow engagement with the inner surface ofthe substrate and lifting of the substrate to provide a positive seatingon the chuck housing 10 due to pressure of the bulb expansion as well asthe inherent elastic and frictional properties of the bulb material.After processing of the substrate, the actuator 25 of thebulb-stretching member 40 is again moved in the forward direction Athereby lengthening the bulb contour 20 and shrinking its widthdiameter. The configuration effects pulling the bulb outside surfaceaway from the inner surface of the substrate and allowing withdrawal ofthe chuck device 10 from the substrate.

During engagement of the chuck device 10 shown in FIGS. 1-3 with adifferent size substrate 100, 100′, it is preferred that a hermetic sealis created by contact of the bulb outer surface material against thesubstrate inner surface to minimize or prevent fluid migration,especially liquid, into the interior of the substrate.

The chuck device of the present invention may provide severaladvantages. For example, the expandable bulb chuck may embody low massand therefore may not cause excessive heat flow from a thin substrate tothe chuck assembly when placed in an oven. Also, the cost of theexpandable chuck may be low due to the non-precision requirements andthe application of molded parts, thereby greatly minimizing the need formachining. The cost savings may be large when hundreds or thousands ofthe chuck devices are required.

Any suitable rigid or flexible substrate may be held by the substrateholding apparatus of the present invention. The substrate may have acylindrical cross-sectional shape or a noncylindrical cross-sectionalshape such as an oval shape. The substrate may be at least partiallyhollow, or entirely hollow, with one or both ends being open. In certainembodiments, the substrate is involved in the fabrication ofphotoreceptors and may be bare or coated with layers such asphotosensitive layers typically found in photoreceptors. Due to possiblewide range of diameter adjustments afforded by the expandable bulbprovision of the embodiments, the processed substrate may have anysuitable dimensions.

While the invention has been particularly shown and described withreference to particular embodiments, it will be appreciated thatvariations of the above-disclosed and other features and functions, oralternatives thereof, may be desirably combined into many otherdifferent systems or applications. Various presently unforeseen orunanticipated alternatives, modifications, variations or improvementstherein may be subsequently made by those skilled in the art which arealso intended to be encompassed by the following claims.

1. An expandable chuck for holding photoreceptor substrates of variousinside diameters, comprising: (a) a housing having a passageway; (b) aplunger configured to slide within the passageway; (c) a variablediameter resilient bulb having a substantially smooth and continuousouter surface between a first end and a second end, and configured toexpand in diameter in a range from about 24 mm to about 60 mm; (d) astop device extending from an outside surface of the housing, whereinthe stop device is configured to abut an outside surface of a substrateto facilitate a stop for a measured length insertion of the bulb intothe substrate, wherein the plunger is configured to cause the bulb toexpand and to engage the interior of the substrate when the plunger ismoved in a first direction and to contract and to disengage from theinterior of the substrate when the plunger is moved in an seconddirection, and the bulb is configured to expand between a first diameterand a second diameter, each of which is in said range, the firstdiameter corresponding to an inside diameter of a first photoreceptorsubstrate and the second diameter corresponding to an inside diameter ofa second, larger-diameter photoreceptor substrate, wherein the outersurface of the bulb is configured to form a hermetic seal against aninner surface of each of the first and second photoreceptor substratesto prevent fluid migration into the interior thereof.
 2. The expandablechuck according to claim 1, wherein the housing is a hollow tube, pipe,or drum.
 3. The expandable chuck according to claim 1, wherein thehousing defines a housing wall and a plurality of holes are provided inthe housing wall.
 4. The expandable chuck according to claim 1, whereinan end of the housing is threaded to the bulb.
 5. The expandable chuckaccording to claim 1, wherein the bulb comprises a wall material withincreasing thickness toward the first and second bulb ends.
 6. Theexpandable chuck according to claim 1, wherein the plunger comprises arod.
 7. The expandable chuck according to claim 1, wherein an end of theplunger comprises a cone shape tip.
 8. The expandable chuck according toclaim 1, wherein a midsection of the bulb has a durometer numericalhardness ranging from about 25 to about 40 and one or both ends of thebulb have a durometer hardness ranging from about 45 to about
 60. 9. Anassembly comprising a substrate and an expandable chuck, the assemblycomprising: the first photoreceptor substrate; and the expandable chuckaccording to claim
 1. 10. The assembly according to claim 9, furthercomprising: the second photoreceptor substrate.
 11. The expandable chuckaccording to claim 1, wherein the bulb comprises a wall defining aninterior of the bulb, the wall material having a variable thicknessbetween the first and second bulb ends.
 12. An assembly comprising: afirst photoreceptor substrate having an inside diameter of 24, 40 or 60mm; a second photoreceptor substrate having an inside diameter of 24, 40or 60 mm that is different than the inside diameter of the firstphotoreceptor substrate; and the expandable chuck according to claim 1.13. The assembly according to claim 12, further comprising: a thirdphotoreceptor substrate having an inside diameter of 24, 40 or 60 mmthat is different than the inside diameters of the first and secondphotoreceptor substrates.
 14. A method for grasping photoreceptorsubstrates with an expandable chuck comprising: inserting the expandablechuck into a first photoreceptor substrate; abutting an outside surfaceof the first photoreceptor substrate using a stop device extending froman outside surface of the expandable chuck; expanding a variablediameter resilient bulb of the expandable chuck, the bulb having asubstantially smooth and continuous outer surface and configured toexpand in diameter in a range from about 24 mm to about 60 mm; andforming a hermetic seal against an inner surface of the firstphotoreceptor substrate to prevent fluid migration into the interior ofthe first photoreceptor substrate; removing the expandable chuck fromthe first photoreceptor substrate; inserting the bulb into the interiorof a second photoreceptor substrate having a different inside diameterthan that of the first photoreceptor substrate; and expanding the bulbto engage an inner surface of the second photoreceptor substrate to forma hermetic seal against the inner surface of the second photoreceptorsubstrate to prevent fluid migration into the interior of the secondsubstrate, wherein the inside diameter of each of the first and thesecond photoreceptor substrates is in said range.
 15. The methodaccording to claim 14, further comprising: dipping one of first andsecond photoreceptor substrates in a coating material.
 16. The methodaccording to claim 14, further comprising: contracting the bulb todisengage the bulb from the interior of one of first and second firstand second photoreceptor substrates; and removing the bulb from said oneof the photoreceptor substrates.